Chapter 7 Kiln Dust
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Page 23
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ##
Page 236
$
%iln ust
© Holderbank Management & Consulting, 2000
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
is osal o( )astes (rom Cement Prodution
*+ INTRD!CTIN
2"7
2# R$%!&'TR( 'S)$CTS * D!+)IN% S&ID ,'ST$ +'T$RI'&S
2"-
2.1
Siss TVA -.
23/
2.2
+P+1+s TCP ea!ing Test
242
2.3
uro4ean #5 38 405 D24 ea!ing Test
243
"# DIS)S'& * %eneral CEMENT PLANT WASTES
243
.# DIS)S'& * KI&N D!STs
2./
+*
isarded ust, its Potential and Drawbacks
246
4.2
Met!ods o( #n$Plant is4osal o( 7ntreated %iln ust
248
4.2.1 4.2.2
1ddition o( ust to Cement 8eturning to %iln a(ter 9ranulation or Com4ation
Met!ods (or #n$Plant 7se o( %iln ust a(ter 8emo:al o( 1lkalis
+3
248 249 252
4.3.1
8emo:al b" Sim4le ea!ing
252
4.3.2
8emo:al b" Passama;uodd" Te!nolog" 8eo:er" Srubber
255
.#"#"
Remoal b1 1u
ed ?ed 8eator
256
8e4orted Plant
+
2./
++*
1s =ertili>er
2./
++2
1s 8a Material (or 1rti(iial (NV!r"# Soil
260
++3
1s 1s4!alt =iller
262
# Disposal o3 41pass Dust In )lant !se
#5
/# DIS)S'& * R$*R'CTRI$S
2/" 2/" 2/
/#5
4a6kround
2/
/#2
Materials #n:ol:ed and t!eir C!emial Com4ositions
2/
/#2#5
+aterials Inoled
2/
6+2+2
C!emial Com4osition
2//
6+3
8egulator" 1s4ets @ Manu(aturers Sa(et" ata Sheets
2/7
6+
#n$4lant ret ratories dis4osal
2/7
6
*
6++2
Plant “1”
26A
Plant “?”
26A
7# Re616lin o3 spent 6ement kiln re3ra6tories
© Holderbank Management & Consulting, 2000
2/-
Page 23'
Holderbank Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
/+ 144endi
+2A0
/+*
144endi< 144endi< #a
2A0
/+2
144endi< 144endi< lb
2A*
/+3
144endi< 144endi< #
2A2
/+
144endi< 144endi< lb
2A3
Page 236
© Holderbank Management & Consulting, 2000
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
*+
#5T8B7CT#B5
)!ereas natural 4roesses generall" our in "les, in !i! t!e aste 4roduts reated do not !arm t!e bios4!ere, t!e same annot be said (or !uman ati:ities at toda"s !ig! 4o4ulation densities+ T!e ement industr" is no e<e4tion in t!at it generates astes !ose 4ro4erties range (rom being an unsig!tl" nuisane to being de(initel" to
)astes generated in Cement Plants
Solid )astes
i;uid )astes
9aseous )astes
o:erburden, eart!
kiln dust, b"4ass dust mill dust sul4!ur absorbent reDet 4rodution
used retratories leaning dust sra4 iron rubber astes Et"res, beltsF
test 4risms @ ubes rainater @ as! ater seage ater oils @ greases @ emulsions
laborator" !emials
sol:ents
C02, 5B8, SB2, H"droarbons, et+
#n t!e 4resent artile t!e main em4!asis ill be 4laed on t!e management o( t!e large tonnage astes namel" re(rator" tear out and t!e :arious t"4es o( kiln dusts+ 5o mention ill be gi:en to t!at aste generated in t!e largest ;uantities, namel" CB2 emissions, o( !i! t!e ement industr" is a signi(iant but not t!e maDor ontributor+
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Page 23A
8Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
2#
R$%!&'TR( 'S)$CTS * D!+)IN% S&ID ,'ST$ +'T$RI'&S
#n t!e 4ast most manu(aturing and 4roessing industries sim4l" dum4ed t!eir aste materials, eu4!emistiall" alling t!em “land(ill”+ T!e" did t!is beause it made eonomi sense and an aareness o( t!e aom4an"ing burden to t!e en:ironment e
Toda" t!e situation !as !anged+ n:ironmental aareness is onl" all too 4resent and t!ose !armlessl" dum4ed astes o( "ester "ear are no beoming t!e 4otential en:ironmental time$bombs o( toda" and tomorro+ Man" a ement 4lant is going to be on(ronted it! a bill (or leaning u4 its dum4ed materials, osts !i! ill ertainl" be a multi4le o( t!e sum originall" “sa:ed”+ 5o ement om4an" in a de:elo4ed ountr" is toda" going to be alloed to ind u4 its o4erations until it !as made ertain t!at all t!e materials it dum4ed during its o4erational li(etime are in a (orm !i! 4oses no t!reat to t!e en:ironment+ Some e
2#5
S9iss TG1-.
T!e Siss )1 regulation o( eember *--0 is a t"4ial e
Page 23/
© Holderbank Management & Consulting, 2000
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
Table 2:
S9iss Dumpin Reulations (TVA1 ;;0< Compositional Re=uirements
Stone like Material EJF H20$soluble substanes EJF Brgani material EJ CF Pb E44mF Cd E44mF Cu E44mF 5i E44mF Hg E44mF Ln D44mD i4o+ org+ Cl om4ods+ E44mF 9as (ormation it! H20 8eation it! sel(, H20,air 5eutral, Ca4ait" EMol@kgF T!e (olloing building material an be inluded in an
-. 0,.
K
. .
.00 *0 .00 .00 2 *000 *0 none none *
inert substane de4osit'
onrete, tiles, asbestos ement, lass masonr" and road onstrution astes+
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Page 23-
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
1s ?a
0+00* 0+.0
0+*0 .+00
Pb Cd Cr$#ll Cr$G# Co Cu
0+*0
*+00
0+0* 0+0. 0+0* 0+0. 0+20 0+20 0+00. 0+.0 0+20
0+*0 2+00 0+*0 0+0. 0+0. 2+00 0+0* .+00 2+00
Hg Ln Sn
Materials !i! ma" be de4osited in inert substane dum4s an eit!er be unreati:e substanes as de(ined in t!e mentioned tables or “building astes” su! as onrete, tiles, asbestos ement 4roduts, glass and masonr"@road onstrution astes+ Materials su! as metal, 4a4er, ood, and te
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
T# C"anide =luoride
not s4ei(ied
5itrite Sul4!ite Sul4!ide P!os4!ate CN HCs BC ClSo#N 4H Galue CC' dissol:ed organi arbon H9' !"droarbons BC' l"4o4!ili organi !lorine om4ounds Cl Sol' !lorinated sol:ents N
0+0* *+00 0+*0 0+*0 0+0* *+00 20+00 0+.0 0+0* 0+0* 6$*2
not s4ei(ied 0+*0 *0+00
*+00 *+00 0+*0 *0+00 .0+00 .+00 0+0. 0+*0 6$*2
1s a result o( t!ese regulations t!e (olloing restritions 4re:ent Ein Sit>erlandF t!e dum4ing o( aste materials su! as kiln dust and re(ratories'
H20 soluble substanes I 0+. >? res4 alkali !lorides and sul4!ates
total Pb and Ln le:els o:er .00 44m due to use o( alternati:e (uels and ra material om4onents
soluble Pb and Ln limits e<eeded due to use o( alternati:e (uels and ra material
I
.+0 J e<eeded due to 4resene o( soluble
om4onents+ soluble Cr limit e<eeded in t!e ase o( s4ent magnesia$!rome re(ratories
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## $ %iln ust
2#2
$#)#'#@s TC&) &ea6hin Test
#n t!e 7S1 t!e dis4osal o( kiln dust and o( s4ent kiln re(ratories is mainl" b" dum4ing t!e re(ratories, o(ten in 4lant e
sent, is deided b" t!eir be!a:iour aording to t!e To
Cd Cr
*
.
Cu CrHg
0+2
5i
A0
Pb
.
Se
*
Sb
*
T#
A
Ln 1s an be seen t!e elements de(ined are Eit! one e<e4tionF trae to
T!e one e<e4tion is Cr !i!, as Cr203, is a maDor o
J Cr203+
S4ent magnesia$!rome briks are t!ere(ore not likel" to 4ass t!e TCP test (or dis4osal in a munii4al garbage dum4 and !ene ill !a:e to be treated be(ore su! a dis4osal it! ensuing osts+ 1 !ange to re( ratories o( t!e !rome$ore (ree magnesia$s4inel or doloma t"4es a:oids t!is dis4osal 4roblem om4letel"+
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
$uro ean DIN "-.0 D2. &ea6hin Test
2#"
1ording to t!is regulation t!e (olloing onentrations o( Cr6 ditate t!e dis4osal o( all astes, but es4eiall" t!ose ontaining !romite ore Emagnesia !rome briksF as (ollos'
"#
I0+*mg@#' K
0+* mg@# I0+. mg@#'
K0+. mg@#'
in !ouse!old garbage dum4 in to
s4eial treatment or must be dum4ed underground
DIS)S'& * %$N$R'& C$+$NT )&'NT ,'ST$S
B( t!e general astes generated in ement 4lants e
© Holderbank Management & Consulting, 2000
Page 2
g
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust
O
+ D
P $i
#
'D+ H
$
,orkshop =errous 5on$(errous 8a s
Waste Wood )lant =errous 5on$(errous Masonr" Pa4er, st"ro4or )ater Re3ra6tories Cuttings
Tear out %arae T"res Bil @ 1ir (ilters )aste Bil aborator" i;uid aste Solid aste 8adioati:e soure Aarious 9lass i !t tubes
Page 2
t 2t
Sa4 metal Sa4 metal 9arba e ininerator
0t 3t 60t 0+.t
Sra4 metal Sra4 metal
Mi< bed 9arbage ininerator
Mi< bed *0 .00 Ga 0+.t
.0 kg *000* *0* *0*
*00
Mi< bed Mid bed
Siggent!al Siggent!al )aste oil dealer S4eial olletion S4eial olletion Su !er oal olletion S eial Colletio
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“Holderbank” Cement Seminar 2000 +aterials Te6hnolo1 ## %iln ust $
Table 7:
,aste to be Disposed at Ciminas )lant
Internal use 1sbestos om4onents Cement e< s4illages Clinial astes 9lass am s 8ags I lot!s 8e(ratories Cr ontainin )astes (rom !aroal Sa< e< sand blastin
Crus!ed, added to ra mill 8eturned ro 4roess #ninerated in ontainers Crus!ed, added to ra mill 1dded to ra mill #ninerated in ontainers Crus!ed, added to ra mill 1dded to ra mill :ia la" 1dded to ra mill
1skarel oil Clot!es @ s!oes @ !elmets Conrete ubes =ibre glass =ilter elements #ron e< slag Metal I eletrial sra4 Bils @ greases Pa4er e< o((ie Plastis 8e(ratories 8ubber @ ar batteries
#t is t!e dis4osal o( t!e larger ;uantities o( ement 4lant s4ei(i astes kiln dust Eu4 to 300BBB t4a at one 9rou4 4lantF and s4ent re(ratories Eu4 /00 tons at some 9rou4 4lantsF t!at must reei:e t!e greatest attention+ )!ereas re(ratories are onsumable items and it is understandable t!at t!ere ill be remnants to be dis4osed o(, t!is is not t!e ase it! kiln dusts+ #n (at most 9rou4 4lants do not !a:e to disard dust and t!ose atuall" doing so are (ored to do so (or se:eral reasons'
4rodution in et kilns o( loEerF alkali ements (rom ra materials !i! do not !a:e
su((iientl" lo alkali le:els to 4rodue su! ements it!out t!e disarding o( dust use o( a b"4ass in dr" 4roess kilns !en t!e ra materials !a:e a too !ig! Cl ontent
to 4re:ent t!e (ormation o( rings in et 4roess kilns aused b" a molar e<ess o( SB3 o:er alkalis+ Most o( t!e dust disarded in t!e 9rou4 is generated at et 4lants in t!e 7S1 and Canada (or t!e 4rodution o( lo alkali ements and t!us in ountries !ose standard s4ei(iations still do not allo t!e inor4oration o( kiln dust into ement+
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8Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
+
DIS)S'& * KI&N D!STS
.#5
Dis6arded Dust its )otential and Dra9ba6ks
T!e total ;uantit" o( dust disarded annuall" in t!e “Holderbank” 9rou4 amounts to some *+/ mio+ t4a, it! t!e ;uantit" 4er 4lant ranging (rom >ero Emost asesF to o:er 200BBB t4a at a (e 5+ 1merian 4lants+ #n t!ese latter ases t!e kiln (eed I linker (ator an be as !ig! as *+-* !i! means !a:ing to 4roess e<essi:e ;uantities o( kiln (eed and a (aster de4letion o( t!e reser:es+
T!e !emial om4osition o( t!e disarded kiln and b"4ass dust :aries it! kiln t"4e as ell as (rom (rom 4lant to 4lant+ etails main o
+oQ
3*+3$3A+-
3+.
+3$*3+3
/+-
.+2$2/+6
*.+6
3+/$33+/
22+6
2*+/$2A+0
2+
Si02
-+0$*6+/
*3+*
*3+*$*6+
*+
+-$2*+0
*+0
3+.$*/+3
*3+3
A+6$**+3
-.
1*203
2+2$6+6
+*
3+0$+.
3+A
*+*$-+0
3+A
*+$6+-
3+-
*+6$3+*
2+-
=e203
*+2$3+3
2+2
*+2$2+.
*+A
0+$3+A
*+.
0+6$+3
*+-
*+*$*+A
*+
CaB
3/+6$.+A
2+2
+$60+/
.2+3
*+-$.2+A
36+*
*0+6$.3+/
*+A
3*+A$-+6
0+2
MgB
0+A0$2+
*+
0+/0$2+A
*+A
0+$2+6
*+0
0+3$+.
*+3
*+3$*+3
*+3
SB3
0+0$2+
0+A.
2+6$+/
3+6
*+3$32+2
*2*+*
0+6/$36+A
6+3
6+0$*+/
*0+
%20
0+3.$2+A
*+0A
+*$*2+6
/+/
3+$3.+2
*3+2
0+A-$3/+*
6+0
0+//$*.+/
/+3
5a20
0+0A$0+30
0+*A
0+*A$*+6
0+62
0+*/$2+6
*+*
0+*2$*+*
*+3
0+0A$*+3
0+6-
Cl
0+0$0+6/
0+2.
2+3$A+*
+2
0+*0$2+0
0+/*
0+0A$*0+/
*+3
0+//$*+3
0+6-
*+3$/+/
.+*
=ree lime
0+00$0+.
0+*2
2+6$3*+*
+2
0+A*$A+A
6+32
0$*A+-
6+33
R+ #
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust
Q S'+ #
'*
$
Selenium
0+62
5M
2+23
6
2+6/
2/+*
30A+00
.
5M
T!allium
0+0*
*+0/
2+6/
32
*+0
3+2
AA6+00
/-
2J
Cadmium
0+03
0+3
*+*2
2
0+*
*0+3
.-+6
/*
3J
*
*2
A.
/2
3
3
A3-0
-.
3J
5M /AJ
ead
0+A
5M
+0
2
0+3
5M
3+
-
Sil:er
6+A.
-+20
*-+-0
-3
+/
*0+.3
0+A0
-2
1rseni
5
19
71
54
2
18
159
50
106%
Nickel
10
31
129
85
1
22
60
65
141%
Barium
91
280
1402
94
35
172
767
95
163%
1.13
305
0.65
3+.
-
174%
A6
22
-3 -
*
2-3
-.
1ntimon"
Berrylium
0.32
C!romium
2.
0.13
/
*/.J
8e(rator"
Notes:
*F <lude non$detetable :alues 2F 5M indiates a:erage not meaningful beause o( large number o( non$detetable :alues 3F 5o+ indiates number o( deteted :alues
%iln dusts, alt!oug! disarded b" a (e 4lants an, in s4ei(i ases, 4ossess !arateristis t!at make t!em o( interest to ot!er uses+ T!e most im4ortant 4ro4erties are'
lo 4rie t!e :er" (ine 4artile si>e @ !ig! absor4ti:e a4ait" neutralising 4ro4erties due to t!e 4resene o( CaCB3 and (ree CaB en!aned le:els o( %20 and SB3
ontent o( !"drauliall" ati:e om4onents T!ese 4ro4erties !a:e lead to 4ro4osals being made (or using ement kiln dust in t!e (olloing a44liations'
absorber material
(iller om4onent in ement and as4!alt neutrali>ating agent (ertili>er@agriultural lime stabilisation o( mud (rom oil drilling substitute (or lime in seage sludge deatering
aste stabili>ation e
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Page 2A
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust
[.JI.11:1:1:Ui
$
glass manu(ature
rearing attle 4rodution o( soil re4laement 4rodution o( lo grade binder
asat litter Here it must be em4!atiall" stated t!at onl" in e<e4tional ases !as ement kiln dust atuall" been used (or an" o( t!e abo:e a44liations in large iuanties and o:er man" "ears+ 5o uni:ersall" ae4table uses !a:e "et been loated (or kiln dusts outside o( t!e ement 4lant and t!eir dis4osal 4roblem !as :et to be sol:ed+ .#2
+ethods attnB)lant Dis osal o3 !ntreated Kiln Dust
.#2#5 1ddition o( ust to Cement T!e most ost$e((eti:e met!od o( using kiln dust is b" inor4orating it into ement+ T!is 4ratie as alloed earl" on in a (e national standard s4ei(iations in uro4ean ountries, !i! in *-/- resulted in A 9rou4 4lants em4lo"ing kiln dust in t!is manner+ T!e ;uantit" in:ol:ed at single 4lants :aried (rom a minimum o( 0+ t+J to a ma
**@1
-0B500
7@?
/B7;
SC4&D*
T
/B20
SBiBC4&BiBDE* F25 B"
IllG'
3.$6
3.$6.
IllG4
20B".
/0B-0
$
IllGC
B5;
-5B;
$
$
IA
60$-0
AG'
0$6
5-B"0
5-B"0
AG4
20B";
"0B0
"0B0
0$0
$
$
$
$
0B
$
$
$
$
0B
$
$
$
$
$
0B50
0B
$
$
$
$
0B
$
$
$
$
0B
#
0B
*F Galues in t!e table re(er to ement nuleus, e<luding alium sul4!ate and additi:es 2F Minor additional onstituents ma" be (iller or ma" be one or more o( t!e main onstituents unless inlueded as main onstituents 3F Portion o( silia dust is limited to *0J in t"4es #ll@1 and #ll@? F Portio o( (iller is limited to *0J in t"4es #ll@1 and #ll@? =or t!ose ountries in !i! t!e loal standard s4ei(iations do not allo t!e addition o( modest additions o( kiln dust as in 5G *-A$*, ement om4anies s!ould, b" ati:e 4artii4ation in standards ommittees, attem4t to bring about t!e neessar" !anges in t!e national standard+
8Holderbank” Cement Semi nar 2000 Materials Te!nolog" ## %iln ust $
$
+2+2
8eturning to %iln a(ter 9ranulation or Com4ation
ssentiall" t!is met!od 4re4ares kiln dust (or re$entr" into t!e kiln b" sim4l" inreasing t!e 4artile si>e, eit!er b" granulation E*$2 mmF or b" bri;uetting it into long t!in rods+ 1s (ar as is knon t!e granulation met!od onl" (ound one 4ratial a44liation, on kiln / at Bbourg, but as not needed (or t!e larger kilns ; and *0 as t!e introdution o( standard s4ei(iations, !i! alloed t!e addition o( dust to ement, made its use irre:elant+ T!e la"out o( t!e kiln / granulator ES!ugiF is s!on in =igures * and 2+
© Holderbank Management & Consulting, 2000
Page 2-
Ci i i Oi ii i
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
=igure *'
9ranulater (or 4rodution o( (ine granulated 4oder E* $2 mmF
D$%VE MBTB8
PB)8 i5T
& I#
C
#+
1.
t
U
$'' $'TATA(LE M%)E$ (LADES
+$++
*$AN+LATED
P$'D+CT
Page 2.0
© Holderbank Management & Consulting, 2000
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,&"-/rbak C// S/!ar 2000 Materials Te!nolog" ## %iln ust
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:4 7..I
+ I
$
=igure 2'
ust iruit, Slurr" iruit, Mi
0
3 U+
'+
$
H7 $
ID +A
/
$9 !s 11
*@
52 55 U+
U
U
UU
S#4rr c!rc4!3 5 S4r8/ 3a0k % S!-" E '/r-"w 2 (lotar" a-/ : S-4rr; <42< 3 6// scr/w ( S-4rr; !0=/c3"rs 4 S3a!0-/ss s3//- c743/ 9 S-4rr; %0=/c3"rs 30 Sc748- b-/0/r
D4s3
c!rc4!3
© Holderbank Management & Consulting, 2000
M!>34r/ a0. c"r0 p r/ss/ c %r c u %
a!r
M!>34r/ "43-/3 32 10=c3!"0
Page 2.*
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## - %iln ust
1s an be seen, t!e granulator onsists o( a :ertial "linder in !i! a onentri s!a(t is 4laed, rotating at a s4eed beteen *2BBB and 3BBB r4m+ 1tta!ed to t!e s!a(t are se:eral grou4s o( kni:es !ose angle to t!e s!a(t is ontinuousl" :ariable+ To 4re:ent t!e granules stiking 4ermanentl" to t!e "linder all t!e latter is lined it! a de(ormable neo4rene liner !i! an be de(ormed (rom t!e outside b" using 4neumatiall" 4oered rollers, so ausing an" de4osits to (all o((+ %iln dust and a binding li;uid are introdued into t!e granulator, !i! b" t!e ation o( t!e rotating kni:es are (ormed into small granules, a residene time o( 0+. to * se+ being su((iient (or granules o( 0+. mm to *+.mm, ma<+ 2 mm in diameter+ T"4iall" (or a granulator o( *0 t@! a4ait" onl" se:eral kg o( dust are 4resent in t!e granulator at an" one time, t!us re;uiring an aurate and reliable dosage o( bot! kiln dust and binder+ 5ormall" t!e kiln dust is itsel( stik" enoug! so t!at ater alone an be used as granulating (luid+
1t t!e Bbourg 4lant t!e use o( e;ual ;uantities o( dust and slurr" alloed t!e !ole o( t!e dust 4rodued in kiln / to be granulated and (ed bak to t!e kiln+ T!e return o( t!e dust in t!is a" alloed t!e ater ontent o( t!e slurr" (ed to t!e kiln to be redued b" some 2 to 3 J and inreased t!e ;uantit" o( t!e dust generated about 2 to %. To 4re:ent t!e granules (rom stiking !en being (ed into t!e kiln :ia t!e *2 m tube, t!e" ere !eld in sus4ension in a arrier gas stream+ T!e :eloit" o( t!e gas sus4ension as about - to *0 m@s and t!e e
Met!ods (or #n$Plant 7se o( %iln ust a3ter Remoal o3 'lkalis
+3+* 8emo:al b" Sim4le ea!ing 1n earl" met!od E*-63F (or t!e treatment o( et kiln dust, so as to allo its return to kiln, is t!e lea!ing s"stem de:elo4ed and used at Holnams undee 4lant in t!e 7S1+ 1s (ar as is knon t!is is t!e onl" lea!ing 4lant o( t!is t"4e in o4eration+ Here some 3.0 t4d dust are olleted dail" (rom bot! o( t!e 4lants 1 .00 t4d et kilns+ ?e(ore t!e installation o( t!e bag (ilter in t!e *--0s, t!e oarser dust taken (rom t!e smoke !amber and t!e (irst to om4artments o( t!e eletro(ilter as returned to t!e kiln b" insu((lation at a rate o( about *0 t4! t!roug! t!e burner 4i4e+ T!e remaining (ine dust it! !ig!er le:els o( :olatiles E(rom !ambers 3 and F as 4roessed in t!e lea!ing 4lant, Esee =ig+ 3F in !i! o:er A0 J o( t!e alkalis ere remo:ed using ;uarr" ater+ T!is lea!ing 4lant is still o4erating toda" but t!e eletro (ilter !as sine been re4laed b" a bag t"4e+
“Holderbank Cement Seminar 2000 Materials Te!nolog" ## %iln Dust $
*iure ":
Dust &ea6hin S1stem
R', S&!RR( &$'CH$D 7ST S788 D!ST CH1M?8
++CT8BST1T#C K&N
7ST BACK TB %LN
U
&, '&C'&I D!STBS,RR(
D!ST BIN
1CH#59
H20
TANK
TB DR'IN
D!ST C ,'T$R MDC
© Holderbank Management & Consulting, 2000
Page 2.3
O LJ
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust
I J
l
5:.’ I
$
T!e kiln dust is slurried bat!$ise in a mi#
1n im4ortant (ator (or t!e ontinuing o4eration o( t!e lea!ing 4lant is ensuring t!at t!e e((luent om4lies it! t!e ater 4ollution regulations+ #n t!e situation at undee t!e aste ater dis4osal 4roblem as to$(old, namel" t!e !ig! 4H :alue o( t!e lea!ing 4lant e((luent and t!e !ig! H2S le:els o( t!e ;uarr" see4age ater+ T!e to 4roblems ere redued to one b" using t!e ;uarr" ater (or t!e lea!ing o4erations+ T!e e((luent (rom t!e lea!ing 4lant !as initiall" a 4H :alue o( *2+. and ontains S, SB, %, 5a and Ca ions+ #t is neutrali>ed b" using steel mill aste 4ikling aid and (errous sul4!ate 4roduing CaSB and =eEBHF2, it! t!e H2S being on:erted into insoluble sul(ides+ T!is treated e((luent is t!en dis!arged into a s"stem o( t!ree lagoons in t!e mined$out ;uarr" !ere t!e solids settle out and t!e ater is t!en aerated and lari(ied+ Part o( t!is treated ater is used (or la" sli4 4re4aration, t!e rest being dis!arged into t!e ri:er under state regulations+ 1s an be seen in Table lit!e o4erating 4ermit o( *-63 does not mention limits (or t!e !ea:" to
*+
But(all 00* =lo Total sus4ended solids Total dissol:ed solids Bil and grease =eal oli(orm bateria Total #ron$Potassium H"drogen sul(ide 4H
2+
A.00 m3@d 20 30 44m *
$
.BBB 6BBB 44m 5o :isible (ilm 200 @ *00 rn@# $
ail"
ail" 2 !r+ om4+ ail" 2 !r+ om4+ ail" :isual obs+ B B
)eekl" grab
Mont!l" 2 !r+ om4+ 0+* 44m 6+. B ;#2
)eekl" grab+ ?i!ourl" grab
.00 m3@d
ail" Mont!l" grab Mont!l" grab )eekl" :isual obs+ )eekl" regarding Mont!l" grab
But(all 00* =lo Total sus4ended solids Total dissol:ed solids Bil and grease Tem4erature 4H
5o :isible (ilm
6+. -+. $
,,
Holderbank Cement Seminar 2000 Materials Te!nolog" ** %iln Dust $
+3+2 8emo:al b Passama uodd Te!nolo 8eo:e Srubber
T!is is essentiall" a modern de:elo4ment o( t!e 4re:iousl" desribed lea!ing s"stem and (irst ent into o4eration in *--0 at t!e T!omaston 4lant in t!e 7S1+ #n s4ite o( orld$ide sales e((orts t!is te!nolog" !as onl" been installed at t!e abo:e mentioned 4lant+ T!e la"out o( t!e e;ui4ment is s!on in =ig+ + 1n im4ro:ement o:er t!e undee lea!ing 4lant is t!at t!ere is no dis!arge o( alkali salt e((luent into t!e atera"s, t!ese being on:erted into solid alkali sul4!ate@!loride to be sold as (ertili>er, 4lus distilled ater+ T!e s"stem also inludes srubbing !i! remo:es -0 J o( t!e SB2 (rom t!e kiln e
&a1out o( t!e Passama;uoiD" Srubber
Scrubbed
ehaust out
H'+
+*V++ +
J++
T
A CD !
%iln
ehaust D
+
+
$+
!- // "4
? $
#
D!s3!--/ ster
V )tassium sul$te out
© Holderbank Management & Consulting, 2000
Page 2..
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
#n t!e Passama;uodd" s"stem kiln dust is mier, !i!, using aste !eat (rom t!e reu4erator and redued 4ressure, turns it into t!e desired 4roduts, namel" alkali salts Emainl" %2S0F (or sale as (ertiliser and distilled ater+ #t as also said t!at t!e srubber ould be able to remo:e dioer and o( distilled ater as ne:er demonstrated+
+3+3
8emo:al b" 1u
#n :er" reent times Holnam ln+,orking it! =uller !a:e arried out initial small, 4ilot sale
trials to e:aluate t!e 4ossibilit" o( 4roduing lo alkali linker E5a20 e;:t I 0+60JF (rom kiln dust using t!e =ullers =luid ?ed C% 8eo:er" Proess+ isarded dust (rom Holnams Clarks:ille 4lant, bot! (res! and land(illed, as used (or t!e test !i! demonstrated an alkali :olatilisation rate I 6. J utilising a ma
are 4resented in =ig+ .+
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
*iure :
5-” *luid 4ed CKD Re6oer1 S1stem
*+0+ =15
C %(Q =
W
1',+
I$ “I
$
$ $H
&i@ i6
0 #3B)8
I $
*& I*%%&&%'&R
* R% 'ST / 'S $ $
=#'I*'&'&
I&&&&KL!)&i *&&$SS!T$ &') I
&!
)$R&C&IS )#9T
+'SS*I#CT,R'T$ V*L.+MET$LC R'T$
%'S
S'+)&IN%
SAELPL.A
'N'&(SIs
T&!#&II'S&
=rom t!e results o( t!e trials it an be said t!at'
a linker it! 0+33 J (ree 9aB as obtained a(ter a 3 !r retention time
t!e (luid bed s"stem !as a lo rate o( (ines generation t!is (ine dust, it! t"4ial om4osition .*+.J *E20, *+33J 5a20, 33+2-J SB3 and **+32J Cl, mig!t be suitable as (ertiliser
t!e TCP !ea:" metals in t!e dust a44ears to meet t!e limits o( t!e 8C81 lea!ing test+ 1t one 4lant no being built in g"4t, Pol"sius !a:e (oreseen t!e use o( an au
© Holderbank Management & Consulting, 2000
Page 2.A
C “Holderbank” Cement Semi nar 2000 Materials Te!nolog" ## %iln ust $
+
8e orted Plant
++* 1s =ertili>er T!e (eatures o( kiln dust !i! make it 4otentiall" use(ul as a (ertili>er are its 4otassium ontent, its lime ontent and its aid neutrali>ing a4ait"+ )!en om4ared to 4otassium$lime (ertili>ers 4rodued b" t!e (ertili>er industr", t!e disad:antages o( kiln dust inlude its :ariable !emial om4osition, its loer %20 ontent, its !ig! (ineness and assoiated noduli>ing 4roblems+
#n general a 4otassium (ertili>er s!ould (ul(ill t!e (olloing re;uirements !i! ma" di((er some!at (rom ountr" to ountr"'
s!ould be in nodule (orm
onl" slig!t :ariations in !emial om4osition s!ould !a:e a minimum ontent o( soluble %20 and CaB E#n 9erman" t!e %20 ontent o( 4otassium (ertili>ers s!ould be beteen 0 to 60 J (or t!e !loride t"4es and beteen 2. to .0 J (or sul4!ate (ormulationsF
(or some ro4s a lo Cl ontent is re;uired
ime (ertili>ers s!ould !a:e a 9aB ontent o( beteen 0 to -0 J de4ending on !et!er t!e" onsist o( alium arbonate, burnt lime or !"drated lime+
Bnl" to 4lants ere knon in t!e 4ast to suess(ull" market t!eir kiln dust+ T!ese ere t!e 5C# 4lant at Maastri!t and 1lsen$?reitenburgs lt>e!oe 4lant, !i! sold t!eir dusts as (ertili>ers under t!e “%5C#C1” and “1lsen” brand names+ 5one o( t!ese 4lants toda" sells kiln dust as (ertili>erO t!e lt>e!oe 4lant as losed in t!e earl" *-/0s and at 5C# t!e kiln dust is being legall" added to t!e ement+ )it! regard to t!eir !emial om4ositions t!e dusts (rom t!ese 4lants !ad ;uite di((erent !arateristis as s!on in TabQe *2+ T!e (ertili>er (rom 1lsen as o( t!e 4otassium t"4e, t!at (rom 5C# o( t!e lime$4otassium t"4e, and as an be seen t!ese om4ositions are t"4ial o( t!e dusts (rom man" et and semi$et 4lants+
CB2 SiC2 1l203 =e203 CaB MgB SB3 %20 5a2B Cl
*/ */ 3 3 6
2$6 2$6 0+. *+. 02$0+.$*. 0+* 0+3 32$332$2 2$3 $
$
. . $
$
*
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
=or t!e suess(ul marketing o( kiln dust a :er" large in4ut ma" not be re;uired+ 5C# (or instane did not market diretl" under t!eir on name but did so t!roug! a se4arate om4an" !a:ing a long e<4eriene in t!e business o( 4ro:iding (armers it! (ertili>ers+ T!e" ere able to laim on t!e basis o( ro4 tests t!at barle", turni4s, 4otatoes and sugar
beet 4rodued t!e same "ields as !en on:entional lime or 4otassium sul4!ate (ertili>ers ere em4lo"ed+ #t as e:en laimed t!at sugar beet ontained u4 to 30 J more sugar !en “%5C#C1” as used+ 5C# laimed t!at t!e CaB to %20 ratio o( -'* and t!e 4resene o( alium siliates made t!eir 4rodut es4eiall" :aluable as a (ertili>er+
#n t!e ase o( “1lse,,” t!e om4an" did its on marketing, an e
*iure /:
)romotional &iterature 3or “'lsen” *ertiliMer
%7r KalidNn7er Iiei"t ??'lsen@5 Kali3ilterstaub ranuliert# eiiii darnit !olen Sie
niehr aus #lireiii
?o#en+
%+
Mit diesen Da!##i!ile#l iabe,, er>ieieri Si6 !X!ste,, 9ein,, Ol#I#IP#?.IQ,.i
N*s++us++++"
dis!+
2+.0 U 300
0034..’. III.’ ,h?Ie#005tS IfIS4flI(4I0hhi
740
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9eballie Mra(t 4odeit#
tiirlliren
#leise#iosie #ioWQ##ng U GorraisdY(lglsng ++
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© Holderbank Management & Consutting, 2000
#
Page 3
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ##
$
%iln ust
,,1lsen” %ali(i!terstaub in !arten
Gorteile des granulierten %ali(ilterstaubs groBe
glei!ma(lige Gerleliung o!ne Gertuste
N
dut! Gerstauben oder Gere!en+
Sio44eldungiing
N
U GorralsdYngung
l0BJlge 1usnui>ulig
N
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Streuleistung dut! %reisei
stret,er
N
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%aii(iiterstaub steilt si! diesets !arten Gersu!en und er>ieil 7ber>eugersde # bnisse+
2\
+*+ o4timale 7ngitng mit einern !o! erilgen+ neuen %alld7nger'
N
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male rnleertr[ge Egibe elsen irnmerleder Ger
Hier der ?eeis der andirts!a(tli!en
Apr#irh6# iind *nrrhi?np6int+t %-7<r7s
1lsen %aiilillerslaub graruliert
Mr %orn$ und Stro!erirag
o+ue
lIoIaella7 ;5025-;
5#+
ie Yber>eugenden ?estandteile %aliumsut(at Egaranlierler Mindeslge!ait
30 J lE,BF .+. U A+.J %a#k ECa 0F *+.U 2+. .1. 5elrium E5aF %eHumsullat m#t besonders ginstigem N inltuit ut 9odenslrukiur und Plian>en :ertr$g#i!kei iCaik als ert:olier 5ebenbestandlell N soie ert:olle S4urenelemenle
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+
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$$$++H$+
++2 1s 8a Material (or 1rti(iial E5$GiroF Soil 1n interesting use o( kiln dust, 4resentl" 4ratised in t!e 7S1 is in t!e 4rodution o( arti(iial soil+ T!e kiln dust and b"4ass dust (rom a (e 7S 4lants is being sold to a s4eialist om4an" 5$G#8B !i! mi
$
dail" land(ill o:er material
land and mining relamation land reminerali>ation
!ig!a" embankment onstrution landsa4ing and tur( material
agriultural lime@soil onditioner
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
etails (rom 5$G#8Bs 4romotional literature are s!on in =ig+ / and t!e om4osition o( t!e dust in Table *3+ Table 5":
Chemi6al Composition o3 ?
Si02
57#
1*203
+/A
=e203
*+/
CaB
6*+*
MgB
0+A2
S03
+23
5a20
0+.*
%20
*+.3
Ti02
0+3-
Bl
6+-A
+a# &imit ppm
ppm
1s
.+0
0+003
?a
*00+0
2+
Cd
*+0
0+0.
Cr
.+0
0+2*
Pb
.+0
0+..
Hg
0+2
I0+00*
Se
*+0
0+006
+a# &imit 4 m
ppm
.+0
0+00
?a
*00+0
*+A
Cd
*+0
0+0.
Cr
.+0
0+2.
Pb
.+0
0+6
Hg
0+2
0+003
Se
*+0
0+002
1
.+0
0+0
© Holderbank Management & Consulting, 2000
Page .
U&RP
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust
U.:7#
$
Promotional iterature (or “5$Giro Soil”
=igure /'
/7" s" sim4le+
'
+
@*+ 1
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3+
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5Giro .o6* 4roess oruseirs sludge to soil #ii sesen t!r"s!!our sludge odors+ &ii isa !#S $)'# ))R) EProess to =urt!er Petiue ParirogensF a44rosesi 4roess+
B
++!,++++++ C3!6(lCS+la+
U
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C7..BB
T!roug! ii r*. sim4le+ ileesre4 4roess, a mountin problem an inesirausilbie resour6e#
H+,,
beomes
$
5 Gkrri=PPra##ngg,,es KIrid greater margin r* a#g," 9reet smears NCV%0s #s ared nalkmal! pIn lust on ante r4eob basis
Bdor #ledulion
" U
$+
Pol!ogen ^lii
$
$
@
#ei Copilot Cost
$H
lIaars#d
5 G#,,,,, ! 55#555? +in,tsliuu,u, Is#?? #555 ##rl#,+el,i ## sa #ri#grrl #S##5 #lle4r,s,es. =,sm, i!e n,#n,,#e ...B % nr#rrrd rlilis!alge+ tire 5$G#es
T!e bene(its are lear+
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7 7
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#sU #n#m+n
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oll+er s"stems and +r4eauonalr
?e?R
? I#? V
U
++3 1s 1s4!alt =iller
Bnl" one 4lant in t!e “Holderbank” 9rou4 !as, as (ar as is knon, been able to sell some o( its kiln dust Ea44ro<+ 200 t@aF (or use as a (iller in as4!alt, t!is amounting to onl" *0 J o( t!e a44ro<+ 2BBB t o( dust sold ea! "ear+ Bn t!e basis o( laborator" trials it as asertained t!at onl" t!e dust (rom t!e (irst !amber o( t!e eletro(ilter as 4romising as a (iller, t!e ot!er dusts !a:ing t!e (olloing drabaks'
smoke !amber'
too oarse
!ambers 2, and '
too lo densit" too !ig! solubilit"
C!amber * dust ould be mi
)ae /
© Holderbank Management & Consulting, 2000
“Holderbank” Cement Seminar 2000 +aterials Te6hnolo1 II %iln ust $
Comparison o3 )er3orman6e o3 Di33erent )roportions o3 *iller and Kiln Dust as *iller Component in 'sphalt
Table 5.:
0
0
0
0
0$*. .$2.
0$*. .$2.
0$*. .$2.
.$*0 *3$ *-
*mm 0+0-mm 0+63mm
44arent densit" 0+. $ 0+/ in toluene Porosit" # 30 $ .0
Sensiti:eto ater
Selling +B+l E*.0_CF
K
2-
K
36
#
0
0+.$ 0+6
0+3
30
$
6+.
I*0
I*0
0
K
I*0
I*0
I*0
I3
I3 I*+.
I3 I*+.
I3 I*+.
0+3. $ *+0 0+* $0+2*
3+0 I0+.
I*0
I*0
I*0
0+3/$*+-0
*2+.
0$ .0
.$ 60
32 $3A
./
Solubilit"in ater #?itumen E9etalF
2/ $ 30
#
.+
DIS)S'& * 4()'SS D!ST
#5
In )lant !se
0
0
0
0
.$*0 .$*0 .$*0 .$*0 .$*0 *+.$20+0 *+.$20+0 *+.$20+0 *+.$20+0 *+.$20+0
#
#
0+.
0+3
0+6
0+/
6+0
3+A
3+-
3-+.
0
0
0
0
2+/ I0+. **+6
2+A
2+A
2+. I0+. A+*
.6
I0+.
#
-+6
#
I0+. /+.
D
.0
Q
?eause t!e original 4ur4ose o( a b"4ass is to redue t!e le:els o( Cl or alkalis in t!e kiln s"stem, it is Dust not 4ossible to return t!e dust so e
ignition loss
SiC2 1l203 =e203 CaC MgB
SB3 5a20 %20 Cl
3.+/ *3+. 3+6 *+3 3+2 0+6 0+6 0+3 0+6 0+06
© Holderbank Management & Consulting, 2000
0+3 2*+A 6+* 2+0 66+. *+*
*+0 0+3 0+0+00A
6+. *2+. 2+2 2+. 3*+0 0+ **+0 2+6 */+ **+.
*/+3 /+6 30+* *-*+6
Page A
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## $ %iln ust Table 5/:
?e Pb Cd Cr
41pass dust 6hemi6al 6omposition
$
Cu Mo H Se T# G Nit!out burning t"res
*+0 2*+0 *+0 *6+0 2+0 .+0 2+0 *2+0 0+0. 2+0 +0 *+0
*+6 -A+0 .0N 6+0 -0+0
**+0 2/+0 6+0 3/+0 2+0 .6+0 2A+0 /0+0
*+6 .+0 2* 6+0 .+6 .+. .+6 3+0 3+2
N
0+0 2/+0 A+0 2+0
Se:eral 4lant internal uses !a:e been (ound (or t!e b"4ass dust inluding'
addition at ra material 4re4aration
(eeding to t!e ra meal
addition to BPC and slag ements as alloed b" 5G *-A$* T!e b"4ass dust is added to t!e ra meal onl" !en t!e Cl ontent in t!e kiln (eed (alls to 0+0J to 0+0. > and su((iient dust is added to gi:e a onstant le:el o( 0+0/ > Cl+ T!is ensures a smoot! b"4ass o4eration+ )!en added to ement t!e ;uantities are limited b" t!e re;uirement t!at t!e ma
lo ;ualit" !"drauli binders s4eial binding agents (or salt mining
Page /
© Holderbank Management & Consulting, 2000
“Holderbank” Cement Seminar 2000 +aterials Te6hnolo1 II %iln ust $
/#
DIS)S'& * R$*R'CTRI$S
/#5
4a6kround
Prior to t!e *-/0s t!e dis4osal o( s4ent re(ratories in:ariabl" in:ol:ed dum4ing t!e broken out material in t!e ;uarr"+ T!us onl" monetar" as4ets ere taken into onsideration and an" 4otential burden on t!e en:ironment as ignored+ T!e introdution o( strit dum4ing regulations !as also altered t!is 4ratie but in some ountries an e;uall" undesirable situation no e
HMC I CS is o( t!e o4inion t!at t!e 4lants o( t!e “Holderbank” 9rou4 s!ould aim at being able to dis4ose o( all t!eir s4ent re(ratories b" inor4oration into t!e ra materials+ /#2
+aterials Inoled and their Chemi6al Corn ositions
6+2+* Materials #n:ol:ed
#n t!e idest sense t!e aste materials assoiated it! ement kiln re(ratories must also be inlude t!e 4aking materials in !i! t!e" are deli:ered+ T!is inludes ooden 4allets, 4a4er and 4lasti 4aking, steel and 4lasti drums et+ Su! materials are dis4osed o( it!in t!e (rameork o( a 4lants general re(use one4t Esee C!a4t+ 2F and ill not be (urt!er onsidered+ T!e s4ent re(rator" materials (all mainl" into t!e (olloing ategories'
basi briks o( t!e magnesia and doloma t"4es
!ig! alumina briks (irela" and lig!teig!t insulating briks
dense re(rator" onrete insulating boards
steel 4lates, steel an!ors Most is in t!e (orm o( briks+
© Holderbank Management & Consulting, 2000
Page -
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
6+2+2 C!emial Com4osition T!e !emial om4ositions o( t"4ial ement kiln re( ratories as su44lied are gi:en in Table *A+ Here it an be seen t!at, a4art (rom t!e ele:ated MgB and Cr203 ontents o( some t"4es, t!eir om4ositions are similar to t!e o
reation it! non :olatile 9aB and Si02 (rom kiln !arge
reation it! CB2 and SB2 kiln atmos4!ere Edoloma t"4esF
reation it! it! alkalis and sul4!ates to (orm Cr& om4ounds Emagnesia !rome t"4esF 4ik u4 o( alkalis, sul4!ates and !lorides into o4en 4ores
Table 57:
T1pi6al Cemi6al Cmposition o3 Aarious Classes o3 Re3ra6tories !nused<
=e2B3
0+.A
+-
*+6
0+//
*+/
2+6
CaB
0+-*
*+2
0+*3
./
0+32
*3+-
MgB
/A
A*+.
0+23
3A+6
0+**
*+.
SB3
0+0*
0+0*
0+02
0+0*
0+*
%20
0+02
0+02
0+32
0+02
*+*
0+-
5a20
I0+0*
I0+0*
0+02
0+0*
0+*2
3+A
TiC2
0+0
0+**
3+*
0+02
*+.
*+3
Cr203
0+*.
*2+3
Mn203
0+0*
0+0/
0+0*
0+0/
0+02
0+0.
P20.
0+0A
0+0
2+/
0+02
0+*.
0+0.
I0+0*
I0+0*
I0+0*
I0+0*
I0+0*
I0+0*
Cl
$
$
Page *0
© Holderbank Management & Consulting, 2000
6+3
8e ulato 1s ets I +anu3a6turers Sa3et Data Sheets
)it!in t!e uro4ean 7nion and t!e 7S1 :arious regulations are no in o4eration !i! regulate t!e dis4osal o( s4ent kiln re(ratories+ etails !a:e alread" been gi:en in C!a4t+ 2+ B( im4ortane to ement 4lant re(ratories s4eialists is t!e sa(et" data s!eets t!at most uro4ean re(rator" manu(aturers are no beginning to dra u4+ 1n e
T!ese guidelines are (or onsumers in general and do not take into aount t!e ement kilns a4abilit" o( dis4osing o( its orn re( ratories+ 5ormall" mention is made to t!e 4resene o( Cr+ #n$ lant re( ra6tories dis osal
6+
#n man" 9rou4 4lants, es4eiall" in uro4e, s4ent re( ratories are ost e((eti:el" and sa(el" dis4osed o( :ia t!e kiln, into !i! t!e" are introdued at a ontrolled dosage rate b"'
milling in t!e ra mill or b" milling in t!e oal mill
#n bot! ases t!e s4ent re(ratories (irst re;uire to be rus!ed and an" steel 4lates, s!ims or an!ors remo:ed b" a magnet Eor in some ases b" !andF be(ore grinding T!e rus!ing 4roess an be eit!er arried out in'
e
a mobile rus!er (rom an e
T!e route :ia t!e oal mill is o( s4eial im4ortane (or t!e ase o( s4ent doloma re( ratories in et 4roess 4lants as t!eir inlusion into t!e ra materials ould !a:e an ad:erse e((et on slurr" :isosit" and 4um4abilit"+ #n t!e (olloing e
Plant “1”
#n t!is semi$et 4roess 4lant (itted it! a (ilter 4ress, t!e s4ent briks lea:e t!e kiln :ia t!e grate ooler and are rus!ed :ia t!e linker rus!er+ T!e" are t!en trans4orted on a band, !ere a magnet remo:es an" metal, to a small silo (rom !i! t!e rus!ed re( ratories are eig!ed into t!e ra (eed at a slo ontrolled rate+ T!e aste re(ratories are t!us ke4t it!in t!e 4lant, re;uire no additional !andling and are e((eti:el" out o( sig!t+ 6++2 Plant “?”
#n t!is large et 4roess 4lant t!e s4ent re( ratories are remo:ed (rom t!e kiln :ia a man !ole and are taken b" truk to a o:ered storage+ 1t regular inter:als an e
*iure ;:
InB)lant disposal o3 ,orn Re3ra6tories
$7r03B!H
t
*,an,4B,
r
$00
$$$++
Crs7/r
'$
IhbIt
7i,!b,#t
## iQ V
C@
S!B
@
C"a- M!--
II3I!
ii L,+,5og,t#l Si#oi
8olnQ!#
dim4tngkY!l
$I?ktroIi#?
t
SEd,to,sd,r
C3
=# S"kB.B" %
7#
8,nd4od,
B),#Bd
4oh
1AW
KIWnk??#lo?
R$C(C&IN% * S)$NT C$+$NT KI&N R$*R'CTRI$S
T!e 4!iloso4!" o('
a:oiding I reduing aste, re"ling or don "ling it, generating energ" b" its dis4osal and
(inall" dis4osing o( t!e “ultimate aste”
is no beoming establis!ed in man" de:elo4ed ountries+ )!en a44lied to ement kiln re(ratories all t!ese 4ossibilities, it! t!e e<e4tion o( energ" generation, are in 4rini4le t!inkable+
7nder t!e motto, “not!ing ill be re"led until it is eonomi”, t!e re"ling o( s4ent ement kiln re( ratories does not a44ear to o((er mu! 4otential+ T!e onl" materials t!at ould in t!eor" be om4letel" re"led are t!e small :olumes o( uttings (rom unused briks briks and rest briks !i! ere ne:er installed+ Bne used re(ratories (rom ement kilns are normall" not suitable (or re"ling+ )!en :ieed (rom a 4urel" (inanial :ie4oint lo ost (irebriks ill ne:er be ort! re"ling and onl" !ig! ost ;ualities su! as magnesia s4inel mig!t !a:e some 4otential+ =rom a te!nial :ie4oint used ement kiln re(ratories are ala"s ontaminated it! a !ost o( substanes !i! substantiall" loer t!eir melting tem4erature and so 4re:ent t!eir re$use in ement kilns+ 1t best re"ling means use in a loer or non re(rator" onte
=rom a 4ratial 4oint o( :ie om4ound materials su! as monolit!is ill 4robabl" ne:er be able to be re"led+ T!e re"ling o( dolomite ;ualities ould neessitate t!e resintering o( t!e material beause o( deterioration o( t!e sinter due to !"dration+ #n Qa4an used magnesia !rome briks (rom t!e ement and glass industries are lassi(ied as !a>ardous astes and are returned to t!e su44lier+ T!is magnesia !rome aste is re"led as gunning mi
i i :5 (:l.
:
“Holderbank” Cement Seminar 2000 Materials Te!nolog" ## %iln ust $
/+
1
endies
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1
endi Ia
M1T8#1 S1=T 1T1 SHT 3ollo9in7 -*@*..@C
Code' State'
.0+30+*$0
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ldend(iatton ol t!e substanel4re4aratton and o( t!e om4an"lundertaklng
R$*R'T$CHNIK %mbH
su44aer 1ddress' Tele4!one' Tele(a<' Tele<' in(ormation' mergen" Tele4!one 5o+'
DB"707; %Yttinen? Rudol3B,inkelBStral"e %erman 0..* /;.5 0 %erman1< 05 /;.5 50. -6/ /"? &' 55 RZDBDepartment 05 /;.5 20-< RZDBDepartment 05 /;.5 20-<
5
Com4osit(ond\n(ormat(onon t!gredien
+anesia *+ro,e -ri*
2#5
C!emial C!aratensation'
5#I
C1S$5o+
C!emial name
Conet+ in J
S"#$ol
*30-$/ 5"0-B"5B2
+anesia Chrome ore
0B500 2+. $ 50
n#k n#k#
3
-Ph!sos
n#k n#k#
Ha>ard+ ldentt(iattan
's supplied t!e produ6t is not danerous# Durin handlin 6uttin? rindin? rekingF nonBsili6eous dusts ma" be fo!#&d see also 6hapter -#<# !nder oidisin alkaline operatin 6onditions the 6hromium@ 6ompounds ma" 3orm minor amounts o3 6hromium@ 6ompounds# Chromium 6ompounds are kno9n to 6ause inWur1 to the skin and respirator1 tra6t 9hi6h ma1 lead to aner+ Chromium 6ompounds are 9ater soluble and ma" lead to a=uati6 toi6it1# .
*irst 1id Mea#ur
.#5
+. +6
9eneral in(ormation' in!alation' Skin ontat "es' ingestion' #n(ormation (or t!e otor
S
=ire$l`g!t(ng Measure+
#5
Suitable ing (rom di+ Substan, or Pre4aration itsel(+ Combusiton Produts+ 8esuttng 9ases' S4eial Proteti:e ;ui4ment (or =e(ig!ters'
4.%
.#" 4.4
.+2 .+3
#.
Page *
none Remoe to 3resh air ,ash entl1 9ith soap *lush e1es it! plent1 o3 9ater? seek medial 6are Drink plent1 o3 9ater? seek medi6al 6are none
no restri6tions# 's 4er surroundin area# none none
not neessar"
© Hoiderbank Management & Consulting, 2000
“Holderbank” Cement Seminar 2000 +aterials Te6hnolo1 II %iln ust $
/+2
1 M/
I
endi< lb Hl1 S1=T 1T1 SHT (olloing 91F155FEEC
C"/ 0tate:
ast r/5!s!"D
Se4tember 2.@-.
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S+30+*$0 Se4t+ 2.@-. 2 o( 4
)$RI&$LX -0G )$RI&$LX -" %
A**idental $/-/as/ M/asr/s
'oid dr" s9eepin# ,et material? s9eep up and ba# +inimiMe dust eneration# 7
&a0-%08 and Stora7e
7.1
:2
&a-! S"ra/
S
E><"sr/ C"/"-a-P/rs"a- /ro*tion
8.1
E08!0//008 /asr/s S
8.2
CASNr.
#F
8.3 8.3.1
' small amount o3 dust ma1 be enerated durin handlin# Store dr" and 6ool a9a1 3rom 3ier6e heat that ma1 ause damae to pa6kain material#
Sbsac/
T31e
L!2!
eneral limit 3or dust [ rim< 6hromium@ 6ompounds
+'K5< +'K5<
/ mg#m3 0?5 mGrn"
Ma>!4 c"0c/0ba3!"0 a w"08 <-ac/
P/rs"0a- Pr"3/c3!5/ EJ!</s */0/ra- Pr"/c/ a &;!/!c
M/asr/s
Keep a9a1 3rom 3ood# 4e3ore breaks and at the end o3 9ork 9ash the hands# 'pproed dust respirator re6ommended 9lo:es reommended 'pproed e1e prote6tion re6ommended Sa(et" boots re6ommended
).3.4
$/s
).3.$
Clot+in2:
"
P7;s%ca- a C7/%ca- Pr"
".1.1
A<
".1.
Colour
".1.3
'"r
8.3.2 ).3.3
g+ai
".).
9.9 9.10 9.11.1
Va<"4r Pr/ssr/ 4-k /s!; S"-4b!-!; in Wa/r
".11
Sc%4b!!; !D
".3 ".4 ".$
9.6 ".7 ".).1
solid
re1Bbro9n n#a# Va-/F-a/
M/-! P"!FM/-! $a/ "!-! P"!F"!-! 5lan2e: P-as7<"! -aab!-!; 6solid' 8as %!!" T/<-"s!"0 imit +<<-"s!"0 L!!
9.2.2
$nsure su33i6ient entilation durin handlin#
a 20J6 a 20J6 a a
_
C
+!
*-/0 _ n#a# n#a# not 3lammable n#a# n#a# not eplosie Aol#B> n#a# n#a# V"-..K n#a# rbar 2#;0 $ "#0 9Fc3 not soluble ,29i. n#a#
T/s3!08 M/7"
+aterials Te6hnolo1 II '
-#"
$
%iln ust
endi I6
+'T$RI'& SA6ET 1T1 SHT (olloing -*@*..@C ast re:ision'
Se4tember 2.@-.
Code'
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State' 4age'
Se4t+ 2.@-. 3 o(
)$RI&$LX -0G )$RI&$LX -" 9
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-+*2 9.13 -+* -+*. -+*6 -+*A
4H$Galue in' Parton Coe((iient n$Btanol1ater Gisosit"'
at2B C
Sol:ent Se4aration Test
at
Sol:ent Content Bt!er ata'
*0
Stabdlt" and 8eati:it"
10.1
Conditions to oid'
*0+2 *0+3 *0+
Materials te a:oid' Ha>ardous eom4osition Produts' =urt!er ata'
%3
T">%c"-"!ca- %"ra!"
appro# 50 na.
C
n+a+ n+a+ n#a# none
-" PB)
ei;!t+$J
+anesia 6ontainin bri6ks 6an rea6t 9ith 9ater to 3orm h1drates 9hi6h are nonBhaMardous? but destro" t!e briks me!aniall"+ Minor amounts o( !romium” ma" be (ormed 3rom 6hromium 6ompounds under oidisin and alkaline operatin 6onditions# ,ater none 's supplied the produ6t ist een under eleated temperatures stable#
none *2
olog#al #n(ormation
*2+*
Persisten, and egradabilit"'
*2+2 *2+3
Mobilit"'
*2+
?loaumuleti:e Potential' =urt!er ologial ln(omiatiens'
13
#s4osal Considerations
*3+*
Pauu
13.2
Contamined Paldng Material'
14
Trans4ort %"ra!"
Page *6
persistent# none none 4e3ore undertakin the 9re6kin o3 used manesiaB6hrome re(rator" linins? 6ustomer are adised to ealuate an1 6hanes to t!e produ6t that ma1 be indu6ed b1 the introdu6tion o3 substan6es and operatin 6onditions not under the 6ontrol o3 endors# The produ6t in the supplied or unused 3orm an be disposed as solid nonBhaMardous 9aste a66ordin to national Pa9s and subWe6t to the absen6e o3 6hromium” 6ompounds#
4e3ore disposin eamine that amounts o3 6hromIum@ and dispose t!e produ6t a66ordin to the result o3 this eamination# Combust or dispose
© Holderbank Management & Consulting, 2000
1
/+
endi< lb
M1T8#1 S1=T 1T1 SHT (olloing -*@*..@C ast re:ision'
Se4tember 2.@-.
Code'
S+30+*$B
State'
Se4t+ 2.@-.
4age'
3 o(
)$RI&$LX -0G )$RI&$LX -" P!"sial and C!emial Pro4erties ECont+F
-+*2
-*3
-+* -+*. -+*6
4H$Galuein' Parbtion Coe((iient
-+*A
*0
Stabil#t" and 8eati:it"
*0+2 *0+
**
at2B HC
a
ro<+ *0 log PB)
Giaosit"'
Sol:entSe4aration Test Sol:ent Content Bt!er ata'
*0+3
at at
C C
n+a+ n+a+ n#a# none
eig!t+J
!"drates !i! are nonBhaMardous? but destro1 the bri6ks me6hani6all1# +inor amounts o3 6hromium ma1 be (ormed 3rom 6hromium"@ 6ompounds under oidisin and alkaline operatin 6onditions# Materials ta a:oid' ,ater Ha>ardous eom4osition Produts' none =urt!er ata' 's supplied the produ6t ist een under eleated temperatures stable# To<#olog#al #n(ormation
none 52
olog#al #n(ormation
*L*
Peralstena and egradabilit"'
*2+2
Mobil#t"'
la"
?ioaumulati:e Potantiat
*L
=urt!er ologial #n(omiations'
*3
#s4osal Considerations
*3+*
Produt
*3+2
Contarnined Paldng Material'
5.
Trans4ort #n(ormation
4ersistent+ none none 4e3ore undertakin the 9re6kin o3 used manesiaB 6hrome re(rator" linins? 6ustomer are ad:ised to ealuate an1 6hanes to the produ6t that ma1 be indu6ed b1 the introdu6tion o3 substan6es and operatin 6onditions not under the 6ontrol o3 endors# The produ6t in the supplied or unused 3orm an be dis4osed as solid nonB haMardous 9aste a66ordin to national la9s and subWe6t to t!e absen6e o3 6hromium@ 6ompounds#
4e3ore disposin eamine that amounts o3 6hromium@ and dispose the produ6t a66ordin to the result o3 this eamination# Combust or dispose
© Holderbank Management & Consulting, 2000
Page 2A3
